Method for repairing and improving structural integrity of storage tanks

ABSTRACT

In some a friction welding apparatus includes a vacuum chamber which prevents combustion in a vicinity of a tank, the vacuum chamber formed from a flexible seal between the tank and a housing and a magnetic apparatus that encompasses a perimeter of a damaged area of the tank and a friction welding motor operably coupled to the vacuum chamber.

RELATED APPLICATIONS

This application claims priority to and benefit of copending U.S.application Ser. No. 13/678,668 filed 16 Nov. 2012 under 35 U.S.C. 120which claims priority to U.S. Provisional Application Ser. No.61/582,329 filed 31 Dec. 2011 under 35 U.S.C. 119(e).

FIELD

The present disclosure generally relates to welding apparatus andtechniques.

BACKGROUND

Conventional welding techniques and apparatus can include an ignitionsource, which may ignite combustible materials. An ignition source isparticularly dangerous when repairing defects in petroleum productstorage tanks. Conventional techniques include arc welding, brazing,adhesives, drill and tap, mechanical fasteners, clamps and polymerpatches.

BRIEF DESCRIPTION OF THE DRAWINGS

It will be appreciated that for simplicity and clarity of illustration,elements illustrated in the Figures have not necessarily been drawn toscale. For example, the dimensions of some of the elements areexaggerated relative to other elements. Embodiments incorporatingteachings of the present disclosure are shown and described with respectto the drawings presented herein, in which:

FIG. 1 is an isometric top-side view of a tank having a floating steelroof;

FIG. 2 is a method of a process of tank repair;

FIG. 3 is a flowchart of a method of a tank repair process;

FIG. 4 is a flowchart of a method of a tank repair process;

FIG. 5 is a side-view of a block diagram of a friction welding apparatusthat uses inert gas;

FIG. 6 is a top-view block diagram of a friction welding apparatus thatuses inert gas;

FIG. 7 is a side-view of block diagram of a friction welding apparatusthat uses inert gas;

FIG. 8 is a side-view of a block diagram of a friction welding apparatusthat uses inert gas;

FIG. 9A is a side-view of a block diagram of a friction weldingapparatus that uses a vacuum chamber formed from a flexible seal; ahousing and a magnetic apparatus;

FIG. 9B is a top-view of a block diagram of a friction welding apparatusthat uses a vacuum formed from a flexible seal; a housing and a magneticapparatus;

FIG. 10 is a side-view of a block diagram of a friction weldingapparatus that uses a vacuum chamber formed from a flexible outer seal;a housing and a flexible inner seal;

FIG. 11 is a top-view of a block diagram of a friction welding apparatusthat uses a vacuum formed from flexible seals and a housing;

FIG. 12 is a side-view of a block diagram of a friction weldingapparatus that uses an inert gas chamber formed from a flexible outerseal; a housing and a flexible inner seal;

FIG. 13 is a top-view of a block diagram of a friction welding apparatusthat uses a vacuum formed from flexible seals and a housing;

FIG. 14 is a side-view of a block diagram of a friction weldingapparatus that uses a chamber of inert gas formed from a flexible seal;a housing and a magnetic apparatus;

FIG. 15 is a side-view of a block diagram of a friction weldingapparatus that uses a chamber of inert gas formed from a flexible seal;a housing and a magnetic apparatus;

FIG. 16 is a side-view of a block diagram of a friction weldingapparatus that uses a chamber of inert gas formed from a flexible seal;a housing and an adhesive apparatus;

FIG. 17 is a side-view of a block diagram of a friction weldingapparatus that uses wing-nut tensioners and levers;

FIG. 18 is a side-view of a block diagram of a motor or other rotationalmeans;

FIG. 19 is a top-view of a block diagram of a motor or other rotationalmeans;

FIG. 20 is a motor or other rotational means;

FIG. 21 is a motor or other rotational means;

FIG. 22 is a motor or other rotational means;

FIG. 23 is a pneumatic motor propulsion source;

FIG. 24 is a pneumatic motor propulsion source;

FIG. 25 is a pneumatic motor propulsion source;

FIG. 26 is a pneumatic motor propulsion source;

FIG. 27 is a top-view of a block diagram of a defect perimeter sealingsystem;

FIG. 28 is a cross-section side-view of a block diagram of a defectperimeter sealing system;

FIG. 29 is a cross-section side-view of a block diagram of a defectperimeter sealing system;

FIG. 30 is a side-view of a block diagram of a defect perimeter sealingsystem;

FIG. 31 is a side-view of a block diagram of a defect perimeter sealingsystem;

FIG. 32 is a top-view of a block diagram of a defect perimeter sealingsystem;

FIG. 33A is a side-view of a block diagram of interlocking sections of aperimeter gasket of a defect perimeter sealing system;

FIG. 33B is a side-view of a block diagram of interlocking sections of aperimeter gasket of a defect perimeter sealing system;

FIG. 33C is a side-view of a block diagram of interlocking sections of aperimeter gasket of a defect perimeter sealing system;

FIG. 34 is a cross-section side-view of a block diagram of a layereddefect perimeter sealing system;

FIG. 35 is a side-view of a block diagram of interlocking sections of aperimeter gasket of a defect perimeter sealing system;

FIG. 36 is a side-view of a block diagram of T-channel interlockingsections of a perimeter gasket of a defect perimeter sealing system;

FIG. 37 is an isometric view of a block diagram of T-channelinterlocking sections of a perimeter gasket of a defect perimetersealing system;

FIG. 38A is a cross-section side-view of a block diagram of sections ofa perimeter gasket of a defect perimeter sealing system;

FIG. 38B is a top-view of a block diagram of sections of a perimetergasket of a defect perimeter sealing system;

FIG. 39 is a top-view of a block diagram of sections of a perimetergasket of a defect perimeter sealing system;

FIG. 40 is a side-view of a cross section block diagram of a frictionwelding apparatus; and

FIG. 41 illustrates eight different stud geometries.

DETAILED DESCRIPTION OF THE DRAWINGS

The detailed description below describes methods and apparatus forrepairing and improving structural integrity of storage tanks.

FIG. 1 is an isometric top-side view of a tank 100 having a floatingsteel roof. Tanks are used to store every known hydrocarbon liquid orgas. The tank 100 includes a deck 102, which is the top of the tank 100.In some implementations, the deck 102 is made of steel and floats abovethe contents of the tank 100 through floats that are on the bottom ofthe deck 102. In some implementations, the deck 102 is 3/16 inches ofhot rolled steel. Tanks made of steel are exposed to weather, ocean saltand caustic or acidic chemicals which causes corrosion over time.

Tanks are manufactured in many different sizes but in the implementationshown in FIG. 1 tank 100 is 100 meters in diameter.

FIG. 2 is a method 200 of a process of tank repair. At block 202, method200 includes surveying a deck of a tank such as deck 102 in FIG. 1 toidentify problem and or defect areas on the deck. Thereafter at block204 method 200 further includes a securing a clamp to the deck inproximity to the problem or defect area to begin repair work on thesurface of the deck in the area of the problem or defect area. In someimplementations, method 200 includes using the clamp to apply an axialload to a stud. Thereafter at block 208, method 200 includes rotatingthe stud and at block 210, and at block 210 applying a seal plate to theproblem or defect area on the deck. Alternatives to the stud include athreaded boss, or nut, a pass through apparatus, fittings, nozzles,nodes, zerts and nails.

In some implementations of rotating the stud at block 208, rotating thestud further includes rotating the stud until a weld reaches apredetermined temperature, number of rotations, stud link reduction(displacement), time or combination. In some implementations of method200, method 200 includes deburring the stud after rotating the stud atblock 208. In some implementations of applying the seal plate at block210, compression, injection or a gravity fill seal is used to apply theseal plate.

Advantages of method 100 and other portions of this disclosure includedissimilar metals can be bonded, final strength is greater than eitherof the two metals used, bonding can be performed in hazardousenvironments (ie: explosive environments) and portability for ease ofuse at worksites.

FIG. 3 is a flowchart of a method 300 of a tank repair process. At block202, method 300 includes surveying a deck of a tank such as deck 102 inFIG. 1 to identify problem and or defect areas on the deck. At block302, method 300 includes applying a temporary sealing patch to theidentified problem or defect areas. Thereafter at block 204 method 200further includes a securing a clamp to the deck in proximity to theproblem or defect area to begin repair work on the surface of the deckin the area of the problem or defect area. Thereafter at block 304,method 300 includes attaching a motor, an actuator and a stud to theclamp. In some implementation, humans perform the function of the clamp.Some implementations of using the clamp to apply an axial load to a studincludes using the clamp to apply an axial load to a stud. Thereafter atblock 306, method 300 includes rotating the stud at a predetermined RPMspeed for a predetermined time. At block 308, method 300 also includesdesigning a patch using finite element analysis. Thereafter, at block310, method 300 includes removing the clamp, and at block 312, method300 includes using compression, gravity or an injection seal to apply aseal plate.

FIG. 4 is a flowchart of a method 400 of a tank repair process. At block202 method 400 includes surveying a deck of a tank such as deck 102 inFIG. 1 to identify problem and or defect areas on the deck. At block302, method 300 includes applying a temporary sealing patch to theidentified problem or defect areas. Thereafter, at block 402, method 400includes preparing a work surface in the vicinity of the identifiedproblem or defect areas.

Thereafter, at block 404, method 400 includes positioning a clamp on thework surface in the vicinity of the identified problem or defect areas.At block 406, method 400 thereafter includes installing a stud in a workpiece adapter (WPA). Thereafter at block 408, method 400 includesconnecting the WPA to an actuator. Thereafter at block 410, method 400includes attaching the actuator to a clamp. Thereafter, at block 412,method 400 includes attaching a motor to the actuator. Thereafter, atblock 414 method 400 includes activating the clamp. Thereafter at block416, method 400 includes blanketing the stud with inert gas. In someimplementations, method 400 includes pre-loading the stud axially.Thereafter at block 208, method 400 includes rotating the stud and atblock 310, method 400 includes removing the clamp, and at block 420method 400 includes installing a seal plate.

In one particular method, a deck is inspected, surveyed and measured forseal plate dimensions and lay-out. Then leaks and near leaks areidentified and temporarily leak sealed prior to preparation of workarea. A vacuum clamp is placed over a prepared work area and alignedwith intended lay-out or evacuation is performed by a hand pump, amechanical pump or a simple suction cup design. A work area is cleanedprepared and stud positions are marked. Thereafter, a forging actuatorwith a pre-loaded stud is inserted into a first work chamber position.Thereafter, an inert atmosphere is created to allow the forging to beaccomplished safely. And a required hold down force is generated toallow for the pre-determined load to be applied to the work piece priorto rotation and friction. Thereafter, hydraulics are actuated to achievepre-determined axial load, and a pneumatic rotational device is lockedonto actuator. A controller activates rotation and the friction forgeprocess is sequenced to a timed completion. Actual process is completein seconds from start to cool-down. The unit can be repositioned tocomplete the balance of required fasteners in a similar manner. Once allfasteners are completed, the rigid, mechanically attached seal plate isinstalled. The seal plate can be flexible, such as being a thick rubbergasket with a rigid perimeter bolt plate (akin to a window frame). Themethod provides both positive containment and improved structuralintegrity of weakened or distorted decking.

In general various implementations of the seal include compression,gravity fill and injection. Various attachments can be installed toimprove existing integrity of storage tank including over-lays andstiffeners.

FIG. 5 is a side-view of a block diagram of a friction welding apparatus500 that uses inert gas. Friction welding includes inertial welding,solid phase friction welding, ultrasonic welding or rotational frictionwelding. The friction welding apparatus 500 generates less heat to theextent that combustible materials are not combusted. Examples of theinert gas are nitrogen, argon and helium. The friction welding apparatus500 is positioned over a work surface 502 such as deck 102 in FIG. 1.The friction welding apparatus 500 includes magnets 504 that are placedin direct contact to the work surface 502. The friction weldingapparatus also includes arms 506 that are rotatably attached to themagnets 504 and that are rotatably attached to a body of the frictionwelding apparatus. The friction welding apparatus 500 also includes adrive motor shaft 508 that is mechanically coupled to a motor 510. Insome implementations, the motor 510 is a pneumatic vane motor, oranother motor that is made of materials that do not create sparks or anignition source. Friction welding apparatus 500 also includes anactuator 512 that is removably coupled to an inert gas tank 514. Thedrive motor shaft 508 is mechanically coupled to a WPA 516, and the WPAis operably coupled to a stud 518. A shroud 520 encompasses a portion ofthe stud 518, the WPA 516 and a lower portion of the drive motor shaft508. When the inert gas from the inert gas tank 514 is released into theactuator 512, the inert gas flows through the actuator 512 and down toand through the shroud 520 and then out the bottom of the shroud 520,the worksite where the stud 518 meets the work surface 502 and envelopesthe worksite in a non-combustible inert gas thus preventing combustionin the vicinity of the tank.

In regards to all magnet peripheral seals described in the drawings anddetailed description herein, a magnet with a peripheral seal canimplement an inlet and outlet for injection. As injection occurs,displacement of product will evacuate through the outlet whilesimultaneously being replaced by sealant when sealant is detectedthrough the outlet. The outlet is closed as long as sealant pressureremains below the holding force of the magnet seal. Various sizes of theoutlet are implemented for various needs, which can be straddled with adonut shaped clamp. For mechanical long term repair, a prototype of themagnet can be fairly inexpensive. The motor 510, the actuator 512, thedonut shaped clamp and the shroud 520 operate using positive pressurefrom the inert gas tank 514.

Applications for friction welding of storage tanks include storage tankrooftops, walls and bottoms (floors). Friction welding of storage tankscan performed to repair, improve structural integrity, alter/modify andreconstruct the storage tanks.

FIG. 6 is a top-view block diagram of a friction welding apparatus 500that uses inert gas. The friction welding apparatus 500 is positionedover a work surface 502 such as deck 102 in FIG. 1. The friction weldingapparatus 500 includes magnets 504 that are placed in direct contact tothe work surface 502. The friction welding apparatus 500 also includesarms 506 that are rotatably attached to the magnets 504 and that arerotatably attached to a body of the friction welding apparatus. Thefriction welding apparatus 500 also includes the motor 510.

FIG. 7 is a side-view of block diagram of a friction welding apparatus700 that uses inert gas. The friction welding apparatus 500 generatesless heat to the extent that combustible materials are not combusted.Examples of the inert gas are nitrogen, argon and helium. The frictionwelding apparatus 500 is positioned over a work surface 502 such as deck102 in FIG. 1. The friction welding apparatus 700 includes magnets 504that are placed in direct contact to the work surface 502. The frictionwelding apparatus 700 also includes arms 702 that are rotatably attachedto the magnets 504 and that are rotatably attached to a body of thefriction welding apparatus 700. The friction welding apparatus 700 alsoincludes a drive motor shaft 704 that is mechanically coupled to motor510. Friction welding apparatus 700 also includes actuators 706 that isremovably coupled to inert gas tank 514. The drive motor shaft 704 ismechanically coupled to a WPA 516, and the WPA is operably coupled to astud 518. Shroud 520 encompasses an upper portion of the stud 518, theWPA 516 and a lower portion of the drive motor shaft 704. When the inertgas from the inert gas tank 514 is released, the inert gas flows down toand through the shroud 520 and then out the bottom of the shroud 520,the worksite where the stud 518 meets the work surface 502 and envelopesthe worksite in a non-combustible inert gas thus preventing combustionin the vicinity of the tank.

FIG. 8 is a side-view of a block diagram of a friction welding apparatus800 that uses inert gas. The friction welding apparatus 800 generatesless heat to the extent that combustible materials are not combusted.Examples of the inert gas are nitrogen, argon and helium. The frictionwelding apparatus 800 is positioned over a work surface 502 such as deck102 in FIG. 1. The friction welding apparatus 800 includes a housing 802that is secured to the work surface 502 through a number of clamps 804.A fitting 806 provides a substantially air tight seal between thehousing 802 and the actuator 512. Indeed, the housing 802, the clamps804 and the fitting 806 provide a substantially air tight seal with thework surface 502. The substantially air tight seal is not completelyairtight but in fact provides deminimus passage of gas out of theenclosure formed by the housing 802, the clamps 804, fitting 806 and thework surface 502. The friction welding apparatus 800 also includes adrive motor shaft 508 that is mechanically coupled to motor 510.Friction welding apparatus 800 also includes an actuator 512 that isremovably coupled to an inert gas tank 514. The drive motor shaft 508 ismechanically coupled to a WPA 516, and the WPA is operably coupled to astud 518. When the inert gas from the inert gas tank 514 is releasedinto the actuator 512, the inert gas flows through the actuator 512 anddown into the enclosure, thus enveloping. The worksite in anon-combustible inert gas thus preventing combustion in the vicinity ofthe tank.

FIG. 9A is a side-view of a block diagram of a friction weldingapparatus 900 that uses a vacuum chamber formed from a flexible seal, ahousing and a magnetic apparatus. The vacuum prevents combustion ofcombustible materials. The friction welding apparatus 900 is positionedover a work surface 502 such as deck 102 in FIG. 1. The friction weldingapparatus 900 includes a housing 902 that is secured to the work surface502 through a flexible seal 904. A fitting 906 provides a substantiallyair tight seal between the housing 902 and actuator 512. The housing 902and the fitting 906 provide a substantially air tight seal with the worksurface 502. The friction welding apparatus 900 also includes motor 510.The housing 902, the fitting 906 and the work surface 502 form a vacuumchamber 908 which prevents combustion in the vicinity of the tank. Thefriction welding apparatus 900 also includes a permanent magnet 910 thepermanent magnet 910 including a release lever 912. The permanent magnet910 is placed over seals 914 that encompass the perimeter of the damagedarea 916.

FIG. 9B is a top-view of a block diagram of a friction welding apparatus900 that uses a vacuum formed from a flexible seal, a housing and amagnetic apparatus. The housing 902 of the friction welding apparatus900 includes a hole 917 and a fitting 918 through the housing 902through which a vacuum hose 919 attaches.

FIG. 10 is a side-view of a block diagram of a friction weldingapparatus 1000 that uses a vacuum chamber formed from a flexible outerseal, a housing and a flexible inner seal. The vacuum preventscombustion of combustible materials. The friction welding apparatus 1000is positioned over a work surface 502 such as deck 102 in FIG. 1. Thefriction welding apparatus 1000 includes a housing 1002 that is securedto the work surface 502 through a flexible outer seal 1004. Fittings1006 provide a substantially air tight seal between the housing 1002 andactuator. The friction welding apparatus 1000 also includes flexibleinner seals 1008 that encompass the problem or defect area 1010 in thework surface. The housing 1002, seals 1004 and 1008 and the fittings1006 provide a substantially air tight seal around the work surface 502.The housing 1002, the fittings 1006 and 1008 and the work surface 502create a vacuum chamber 1008 which prevents combustion in the vicinityof the tank.

FIG. 11 is a top-view of a block diagram of a friction welding apparatus1000 that uses a vacuum formed from flexible seals and a housing. Thehousing 1002 of the friction welding apparatus 1000 includes a hole 1112through the housing through which a vacuum hose attaches.

FIG. 12 is a side-view of a block diagram of a friction weldingapparatus 1200 that uses an inert gas chamber formed from a flexibleouter seal, a housing and a flexible inner seal. The vacuum preventscombustion of combustible materials. The friction welding apparatus 1200is positioned over a work surface 502 such as deck 102 in FIG. 1. Thefriction welding apparatus 1200 includes a housing 1002 that is securedto the work surface 502 through a flexible outer seal 1004. Fittings1006 provide a substantially air tight seal between the housing 1002 andactuator. The friction welding apparatus 1200 also includes flexibleinner seals 1008 that encompass the problem or defect area 1010 in thework surface. The housing 1002, seals 1004 and 1008 and the fittings1006 provide a substantially air tight seal around the work surface 502.The substantially air tight seal is not completely airtight but in factprovides de-minimus passage of gas out of the enclosure formed by thehousing 1002, the fittings 1006 and 1008 and the work surface 502. Thehousing 1002, the fittings 1006 and 1008 and the work surface 502 createa vacuum 1008 which prevents combustion in the vicinity of the tank.Friction welding apparatus 1200 also includes tensioners 1202 that passthrough the housing 1002 and are mechanically and rotatably attached tomagnets 1204 that are magnetically attached to the work surface 502. Themagnets 1204 include a release lever 1206 that releases the magnet 1204from the work surface 502.

FIG. 13 is a top-view of a block diagram of a friction welding apparatus1200 that uses a vacuum formed from flexible seals and a housing. Thehousing 1002 of the friction welding apparatus 1200 includes a hole 1112through the housing through which a vacuum hose attaches.

FIG. 14 is a side-view of a block diagram of a friction weldingapparatus 1400 that uses a chamber of inert gas formed from a flexibleseal, a housing and a magnetic apparatus. The chamber of insert gasprevents combustion of combustible materials. The friction weldingapparatus 1400 is positioned over a work surface 502 such as deck 102 inFIG. 1. The friction welding apparatus 1400 includes a housing 902 thatis secured to the work surface 502 through a flexible seal 904. Afitting 906 provides a substantially air tight seal between the housing902 and actuator 512. The housing 902 and the fitting 906 provide asubstantially air tight seal with the work surface 502. Thesubstantially air tight seal is not completely airtight but in factprovides de-minimus passage of gas out of the enclosure formed by thehousing 902, the fitting 906 and the work surface 502. The frictionwelding apparatus 1400 also includes motor 510. Unused fittings in thehousing 902 are fitted with caps to prevent pressure equalization in thevacuum chamber 908. The housing 902, the fitting 906 and the worksurface 502 form a chamber 908 that is filled by inert gas from inertgas tank 514 which prevents combustion in the vicinity of the tank. Thefriction welding apparatus 1400 also includes a permanent magnet 910 thepermanent magnet 910 including a release lever 912. The permanent magnet910 is placed over seals 914 that encompass the problem or the damagedarea 916. Friction welding apparatus 1400 also includes tensioners 1202that pass through the housing 902 and are mechanically and rotatablyattached to magnets 1204 that are magnetically attached to the worksurface 502. The magnets 1204 include a release lever 1206 that releasesthe magnet 1204 from the work surface 502.

FIG. 15 is a side-view of a block diagram of a friction weldingapparatus 1500 that uses a chamber of inert gas formed from a flexibleseal, a housing and a magnetic apparatus. The chamber of insert gasprevents combustion of combustible materials. The friction weldingapparatus 1500 is positioned over a work surface 502 such as deck 102 inFIG. 1. The friction welding apparatus 1500 includes a housing 902 thatis secured to the work surface 502 through a flexible seal 904. Afitting 906 provides a substantially air tight seal between the housing902 and actuator 512. The housing 902, flexible seal 904 and the fitting906 provide a substantially air tight seal with the work surface 502.The substantially air tight seal is not completely airtight but in factprovides deminimus passage of gas out of the chamber 1502 formed by thehousing 902, the flexible seal 904, the fitting 906 and the work surface502. The friction welding apparatus 1500 also includes motor 510. Thehousing 902, the fitting 906 and the work surface 502 form the chamber1502 that is filled by inert gas from inert gas tank 514 which preventscombustion in the vicinity of the tank. Friction welding apparatus 1500also include tensioners 1202 that pass through the housing 902 and aremechanically and rotatably attached to magnets 1204 that aremagnetically attached to the work surface 502. The magnets 1204 includea release lever 1206 that releases the magnet 1204 from the work surface502.

FIG. 16 is a side-view of a block diagram of a friction weldingapparatus 1600 that uses a chamber of inert gas formed from a flexibleseal, a housing and an adhesive apparatus. The chamber of inert gasprevents combustion of combustible materials. The friction weldingapparatus 1600 is positioned over a work surface 502 such as deck 102 inFIG. 1. The friction welding apparatus 1600 includes a housing 902 thatis secured to the work surface 502 through a flexible seal 904. Afitting 906 provides a substantially air tight seal between the housing902 and actuator 512. The friction welding apparatus 1600 also includesmotor 510. The housing 902, the fitting 906 and the work surface 502form a chamber 1602 that is filled by inert gas. Friction weldingapparatus 1600 also include tensioners 1202 that pass through thehousing 902 and are attached to the work surface 502 via adhesive 1702.

FIG. 17 is a side-view of a block diagram of a friction weldingapparatus 1700 that uses wing-nut tensioners and levers. The frictionwelding apparatus 1700 is positioned over a work surface 502 such asdeck 102 in FIG. 1. The friction welding apparatus 1700 includes ahousing 902 that is secured to the work surface 502 through a flexibleseal 904. A fitting 906 provides a substantially air tight seal betweenthe housing 902 and motor 510. The substantially air tight seal is notcompletely airtight but in fact provides de-minimus passage of gas outof the enclosure formed by the housing 902, the fitting 906 and the worksurface 502. The housing 902, the fitting 906 and the work surface 502form a vacuum chamber 908 which prevents combustion in the vicinity ofthe tank. The friction welding apparatus 1700 also includes wing-nuttensioners 1702 that are operably coupled to arms 1704. When the wingnuttensioners 1702 are turned, the tensioners 1702 either increase ordecrease tension on the housing 902, depending upon which direction thetensioners 1702 are turned. The arms 1704 are rotatably attached to eachother and to stationary items, such as vent tube 1706 and clamp 1708.

FIG. 18 is a side-view of a motor 1800 or other rotational means. Motor1800 is one example of motor 510 in the above figures. Motor 1800includes a drive shaft 1802 that extends through the motor 1800. Driveshaft 1802 is one example of motor drive shaft 508. Motor 1800 alsoincludes a torsion spring or balanced spring 1804. The spring 1804 insome implementations is pre-compressed while on-site on a tankrooftopjust prior to use. The spring 1804 in some implementations ispre-compressed using a hand crank, a pneumatic crank or any other crankthat would not create a spark or other ignition source. In otherimplementations the spring 1804 is pre-compressed off-site and away fromthe tank top or even the refinery in general, using any type ofmotorized crank such as an electric crank or a gas powered crank etc.The spring 1804 is operably coupled to a ratchet 1806 that rotatesaround the drive shaft 1802 and that includes a stop-pick 1808. When thestop-pick 1808 is disengaged from the ratchet 1806 by rotating thestop-pick 1808 outside the teeth of the ratchet 1806, the ratchet 1806rotates freely, which allows the drive shaft 1802 to rotate freely underkinetic energy from the spring 1804.

FIG. 19 is a top-view of a motor 1800 or other rotational means. Motor1800 includes a drive shaft 1802 that extends through the motor 1800.Motor 1800 also includes a torsion spring or balanced spring 1804. Thespring 1804 is operably coupled to a ratchet 1806 that rotates aroundthe drive shaft 1802 and that includes a stop-pick 1808. When thestop-pick 1808 is disengaged from the ratchet 1806 by rotating thestop-pick 1808 outside the teeth of the ratchet 1806, the ratchet 1806rotates freely, which allows the drive shaft 1802 to rotate freely underkinetic energy from the spring 1804.

FIG. 20 is a motor 2000 or other rotational means. Motor 2000 is oneexample of motor 510 in the above figures. Motor 2000 includes a driveshaft 1902 that extends through the motor 2000. Drive shaft 1902 is oneexample of drive motor shaft 508. Motor 2000 also includes a torsionspring or balanced spring 1904. The spring 1904 in some implementationsis pre-compressed while on-site on a tank rooftop just prior to use. Thespring 1904 in some implementations is pre-compressed using a handpress, a pneumatic press or any other press that would not create aspark or other ignition source. In other implementations the spring 1904is pre-compressed off-site and away from the tank top or even away fromthe refinery in general, using any type of motorized press such as anelectric press, a gas powered press etc. The spring 1904 is operablycoupled to a stop-pick 1908. When the stop-pick 1908 is rotated outsidethe diameter of the spring 1904, the spring 1904 moves freely andreleases tension on a piston 2002 and moves the piston 2002 thatreleases force on a linear gear 2004, that causes rotation of a gear2006 that rotates the drive shaft 1902, which rotates a WPA 516, whichrotates a stud 518.

FIG. 21 is a motor 2100 or other rotational means. Motor 2100 is oneexample of motor 510 in the above figures. Motor 2100 includes a driveshaft 1902. Drive shaft 1902 is one example of drive motor shaft 508.Motor 2100 also includes a high mass rotating disk 2102, clutch shoes2104, and a clutch plate 2106 that are mounted on an axle 2108, the axle2108 being fixedly attached to the drive shaft 1902. The axle 2108allows the high mass rotating disk 2102 to spin when not in contact withthe clutch shoes 2104. Rotation of the high mass rotating disk 2102 by ameans for accelerating 2110 rotates the drive shaft 1902, which rotatesan actuator 2112, which rotates a WPA 516 which rotates a stud 518. Themeans for accelerating 2110 can be manual, a pneumatic motor or airpressure. When the high rotating disk 2102 is accelerated to apredetermined speed (such as 1000 rpm), the high mass rotating disk 2102is positioned in contact with the clutch shoes 2104 and the energy fromthe high mass rotating disk 2102 is passed through the clutch plate2106, the actuator 2112, the WPA 516, and to the stud 518.

FIG. 22 is a motor 2200 or other rotational means. Motor 2200 is oneexample of motor 510 in the above figures. Motor 2200 includes a driveshaft 1902. Drive shaft 1902 is one example of drive motor shaft 508.Motor 2200 also includes a high mass rotating disk 2102, clutch shoes2104, and a clutch plate 2106 that are mounted on an axle 2108, the axle2108 being fixedly attached to the drive shaft 1902. The axle 2108allows the high mass rotating disk 2102 to spin when not in contact withthe clutch shoes 2104. Rotation of the high mass rotating disk 2102 bypowering a pneumatic vane motor 2202 rotates the drive shaft 1902, whichrotates a gear box 2204, which rotates an actuator 2112, which rotates aWPA 516 which rotates a stud 518. The gear box 2204 allows more kineticenergy to be stored in the motor 2200, because rotational kinetic energyis proportional to the square of the rotational speed. For examplespinning the high mass rotating disk 2102 at 10,000 RPM and using a 10:1gear box reduction allows 100 times the energy to be stored in the motor2200 compared to spinning the high mass rotating disk 2102 at 1000 RPMwithout using a gear box, such as in motor 2100 in FIG. 21. Thepneumatic vane motor 2202 is powered by gas from a compressed gas tank2304. When the high rotating disk 2102 is accelerated to a predeterminedspeed (such as 1000 rpm), the high mass rotating disk 2102 is positionedin contact with the clutch shoes 2104 and the energy from the high massrotating disk 2102 is passed through the clutch plate 2106, the driveshaft 1902, the gear box 2204, the actuator 2112, the WPA 516, and tothe stud 518. As an alternative, pins 2206 can be implemented instead ofclutch plate 2106 to couple or lock plates together. A commonrequirement is approximately 20,000 joules of energy to weld a stud 518.

FIG. 23 is a pneumatic motor propulsion source 2300. The pneumatic motorpropulsion source 2300 is one example of a compressed gas tank 2203 inFIG. 22. The pneumatic motor propulsion source 2300 includes a wheeledcart 2302 that has an air compressor (not shown). A gas line 2304couples the air compressor to a pneumatic vane motor, such as pneumaticvane motor 2202 in FIG. 22. As an alternative, a tank of compressed gascan be implemented instead of, or in addition to, the air compressor.

FIG. 24 is a pneumatic motor propulsion source 2400. The pneumatic motorpropulsion source 2300 is one example of a compressed gas tank 2203 inFIG. 22. The pneumatic motor propulsion source 2300 includes a wheeledcart 2302 that has an air compressor (not shown). A gas line 2304couples the air compressor to a gas accumulator tank 2402 that isoperably coupled to a second gas line 2404 that can be operably coupledto pneumatic vane motor, such as pneumatic vane motor 2202 in FIG. 22.

FIG. 25 is a pneumatic motor propulsion source 2500. The pneumatic motorpropulsion source 2500 is one example of a compressed gas tank 2203 inFIG. 22. The pneumatic motor propulsion source 2500 includes a wheeledcart 2302 that has an air compressor (not shown). A gas line 2304couples the air compressor to a compressed gas tank 2502. The compressedgas tank 2502 can be decoupled from the gas line 2304, in which case thecompressed gas tank 2502 can be coupled through gas line 2508 to apneumatic vane motor, such as pneumatic vane motor 2202 in FIG. 22,friction welding apparatus 1500.

FIG. 26 is a pneumatic motor propulsion source 2600. The pneumatic motorpropulsion source 2600 is one example of a compressed gas tank 2203 inFIG. 22. The pneumatic motor propulsion source 2300 includes chemicalcatalyst tank 2602 in which a chemical reaction creates compressed gaswhich travels through a chemical line 2604 to an injector 2606 of a gasstorage tank 2608. The gas storage tank 2608 is operably coupled to gasline 2610 that is operable to couple to a pneumatic vane motor, such aspneumatic vane motor 2202 in FIG. 22.

FIG. 27 is a top-view of a block diagram of a defect perimeter sealingsystem 2700. The defect perimeter sealing system 2700 has two particularcapabilities. One capability is to provide fill around a defect andanother capability is to provide live load compression. The defectperimeter sealing system 2700 includes a number of perimeter basecomponents 2702 that are arranged around a defect 2704 of a tank. Theentire top of the perimeter base components 2702 are encompassed orspanned by compression panels 2706. The area between the perimeter basecomponents 2702, the surface of the defect 2704 and the compressionpanels 2706 is a field or compression zone 2708. A material is injectedin the fill or compression zone 2708. One example of the injectedmaterial is a liquid polymer. Another example of the injected materialis a sheet compound.

FIG. 28 is a cross-section side-view of a block diagram of a defectperimeter sealing system 2700. The defect perimeter sealing system 2700has two particular capabilities. One capability is to provide fillaround a defect in another capability is to provide live loadcompression. The defect perimeter sealing system 2700 includes a numberof perimeter base components 2702 that are arranged around a defect (notshown in FIG. 28) of a tank. The entire top of the perimeter basecomponents 2702 are encompassed or spanned by compression panels 2706.The area between the perimeter base components 2702, the surface of thedefect and the compression panels 2706 is a field or compression zone2802. A material is injected in the fill or compression zone 2802. Oneexample of the injected material is a liquid polymer. Another example ofthe injected material is a sheet compound. In addition the perimeterbase components 2702 also include a channel 2804 into which the materialthat is injected into the zone 2802 is also injected, or into whichanother material is injected.

FIG. 29 is a cross-section side-view of a block diagram of a defectperimeter sealing system 2900. The defect perimeter sealing system 2900provides live load compression. The defect perimeter sealing system 2900includes a number of perimeter brackets 2902 that are arranged around adefect 2904 of a tank 2905. The entire top of the perimeter brackets2902 are encompassed or spanned by repair plate 2906. The repair plate2906 is held in place by perimeter brackets 2902. In addition theperimeter brackets 2902 also include a channel 2906 into which amaterial such as a sealant is injected. Studs 2908 having nuts 2910 passthrough the perimeter brackets 2902 and into the surface of the tank topor bottom, but not all the way through the tank top or bottom, to holdthe perimeter brackets 2902 in place.

FIG. 30 is a side-view of a block diagram of a defect perimeter sealingsystem 3000. The defect perimeter sealing system 3000 provides live loadcompression. The defect perimeter sealing system 3000 is placed over afloating tank roof 3002 having a lap joint 3001. The lap joint 3001 istypically created during the original manufacture of the tank. Thedefect perimeter sealing system 3000 includes friction forged threadedstuds 3004, at the least one of which is placed on the floating tankroof 3002. The defect perimeter sealing system 3000 also includes aflexible compression gasket 3006 that is placed over the top of thestuds 3004. In some implementations the studs 3004 have unequal lengthsto the extent that tops of the studs are parallel with the plane ofeither portions of the floating tank roof 3001, so that when theflexible compression gasket 3006 is placed on top of the studs 3004 theflexible compression gasket 3006 is also parallel with the plane ofeither portions of the floating tank roof 3001. The perimeter sealingsystem 3000 also includes an offset compression plate 3008 that isplaced on top of the flexible compression gasket 3006. The perimetersealing system 3000 also includes a cover plate 3010 that is placed ontop of the offset compression plate 3010. The perimeter sealing system3000 is adapted to lap joints on tank roof tops.

FIG. 31 is a side-view of a block diagram of a defect perimeter sealingsystem 3100. The defect perimeter sealing system 3100 provides live loadcompression. The defect perimeter sealing system 3100 is placed over afloating tank roof 3002 having a repair lap joint 3001. The defectperimeter sealing system 3100 includes friction forged threaded studs3004, at the least one of which is placed on the floating tank roof3002. The defect perimeter sealing system 3100 also includes a perimeterbase 3102 that is placed over the top of the studs 3004. The studs 3004have equal lengths so that tops of the studs are not parallel with theplane of either portions of the floating tank roof 3001, but theperimeter base 3102 includes an offset portion that is of equal offsetto the lap joint 3001 so that when the perimeter base 3102 is placed ontop of the studs 3004 the perimeter base 3102 is not parallel with theplane of either portions of the floating tank roof 3001. The perimetersealing system 3100 also includes a cover 3104 that is placed on top ofthe perimeter base 3102. The perimeter sealing system 3100 is adapted tolap joints on tank roof tops.

FIG. 32 is a top-view of a block diagram of a defect perimeter sealingsystem 3200. The defect perimeter sealing system 3200 provides live loadcompression. The defect perimeter sealing system 3200 is placed over afloating tank roof 3002 having a defect 3201. The defect perimetersealing system 3200 includes a perimeter gasket 3202. The defectperimeter sealing system 3200 also includes studs 3004. The perimetersealing system 3200 has the dimensions of 8 feet in length and 48 inchesin width however the structure of the defect perimeter sealing system3200 is not limited by those dimensions. The perimeter sealing system3200 is adapted to lap joints on tank roof tops. Perimeter sealingsystem 3200 has long and narrow dimensions to fit through small 24″×36″manways in the walls of the tank.

FIG. 33A is a side-view of a block diagram of interlocking sections3300A of the perimeter base component 2702 or the compression panel 2706of the defect perimeter sealing system 2700. The interlocking sections3300A have a tongue and groove structure.

FIG. 33B is a side-view of a block diagram of interlocking sections3300B of the perimeter base component 2702 or compression panel 2706 ofthe defect perimeter sealing system 2700. The interlocking sections3300B have a cantilevered tongue and groove structure.

FIG. 33C is a side-view of a block diagram of interlocking sections3300C of the perimeter base component 2702 or the compression panel 2706of the defect perimeter sealing system 2700. The interlocking sections3300C have a diagonal tongue and groove structure.

FIG. 34 is a cross-section side-view of a block diagram of a layereddefect perimeter sealing system 3400. The layered defect-perimetersealing system 3400 provides live load compression. The layereddefect-perimeter sealing system 3400 includes a first layer plate 3402that is secured by a stud 3405 to a work surface 502 around a damagedarea 3406 of a tank roof top. The entire top of the first layer plate3402 is encompassed or spanned by second layer plate 3408. The secondlayer plate 3408 is secured to the first layer plate 3402 via studs3410.

FIG. 35 is a side-view of a block diagram of interlocking sections 3500of a cover/compression panels of a defect perimeter sealing system 3200.The interlocking sections 3502 and 3504 each have a vertical flange 3506and 3508 with flat surfaces 3510 and 3512 through which a stud 3514passes and is held secure by nuts 3516 and 3518.

FIG. 36 is a side-view of a cross section block diagram of T-channelinterlocking sections 3600 of a perimeter gasket of a defect perimetersealing system 3200. The interlocking sections 3602 and 3604 each have at-channel 3606 and 3608 with injection ports 3610 and 3612 throughliquid polymer or other adhesive passes and is held secure by stud 3614and nut 3516.

FIG. 37 is an isometric view of a block diagram of T-channelinterlocking sections 3600 of a perimeter gasket of a defect perimetersealing system 3200. The interlocking sections 3602 and 3604 have achannel 3702 into which liquid polymer or other adhesive passes can beinjected.

FIG. 38A is a cross-section side-view of a block diagram of sections3800 of a perimeter gasket of a defect perimeter sealing system 3200.The sections 3802 and 3804 are positioned adjacent to a round topattachment nut 3806 having a threaded hole 3808 that is secured via astud 3810.

FIG. 38B is a top-view of a block diagram of sections 3800 of aperimeter gasket of a defect perimeter sealing system 3200. The sections3802 and 3804 are positioned adjacent to a round top attachment nut 3806having a threaded hole 3808 that is secured via a stud 3810. In thealternative to the stud 3810 and the round top attachment nut 3006, aconventional hex nut 3812 with a washer 3814 can be implemented.

FIG. 39 is a top-view of a block diagram of sections 3900 of a perimetergasket of a defect perimeter sealing system 3200. The sections 3902 and3904 have holes 3906 for studs.

FIG. 40 is a side-view of a cross section block diagram of a frictionwelding apparatus 4000. The friction welding apparatus 4000 ispositioned over a work surface 502 such as deck 102 in FIG. 1. Thefriction welding apparatus 4000 includes a housing 4002 that is securedto the work surface 502 through a number of supports 4004 between thework surface 502 and the housing 4002, the supports 4004 including astud 4006 and a nut 4008. The supports 4004 also include a gasket seal4010 between the support 4004 and the work surface 500. Inert gas 4012can be released into the chamber formed by the work surface 502 issupports 4004 and the housing 4002 the actuator 512, thus preventingcombustion in the vicinity of the tank.

FIG. 41 illustrates eight different stud geometries 4100, such as suchas a flat-end stud 4102, a semi-spherical-end stud 4104, a flanged-endstud 4106, a ruffled-end stud 4108, a pointed-end stud 4110, a concaveor cupped-end stud 4112, and offset-end stud 4114 and an indented-endstud 4116.

The techniques and apparatus of the drawings and detailed descriptioncan be implemented in the energy industry in petrochemical, oil and gas,nuclear, coal and gas power plants, solar and wind, hydro-electric andtransportation of energy products by rail, truck, ships, pipeline andair; the drawings and detailed description can be implemented in theconstruction of buildings, bridges and towers; the drawings and detaileddescription can be implemented in marine construction of ships,commercial and military, submarines, tankers and barges at ship yards,docks, offshore and semisubmersibles; and the drawings and detaileddescription can be implemented in mining, underground, agriculture,grain storage and aviation and space.

The techniques and apparatus of the drawings and detailed descriptioncan be implemented in internal floor applications in which as extendedhose for internal use, 24″ to 36″ max manway's, wherein the procedurefor roof repair and internal repair is the same and if larger patcheswere needed a hole could be cut in the roof to install.

The Abstract of the Disclosure is provided to comply with 37 C.F.R.§1.72(b) and is submitted with the understanding that it will not beused to interpret or limit the scope or meaning of the claims. Inaddition, in the foregoing Detailed Description of the Drawings, variousfeatures may be grouped together or described in a single embodiment forthe purpose of streamlining the disclosure. This disclosure is not to beinterpreted as reflecting an intention that the claimed embodimentsrequire more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive subject matter may bedirected to less than all of the features of any of the disclosedembodiments. Thus, the following claims are incorporated into theDetailed Description of the Drawings, with each claim standing on itsown as defining separately claimed subject matter.

The numerous innovative teachings of the present application will bedescribed with particular reference to the exemplary embodiments.However, it should be understood that this class of embodiments providesonly a few examples of the many advantageous uses of the innovativeteachings herein. In general, statements made in the specification ofthe present application do not necessarily limit any of the variousclaimed inventions. To the contrary, the description of the exemplaryembodiments are intended to cover alternative, modifications, andequivalents as may be included within the spirit and scope of theinvention as defined by the claims. Moreover, some statements may applyto some inventive features but not to others.

The above disclosed subject matter is to be considered illustrative, andnot restrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments which fall within thetrue spirit and scope of the present disclosed subject matter. Thus, tothe maximum extent allowed by law, the scope of the present disclosedsubject matter is to be determined by the broadest permissibleinterpretation of the following claims and their equivalents, and shallnot be restricted or limited by the foregoing detailed description.

1. A friction welding apparatus comprising: a vacuum chamber whichprevents combustion in a vicinity of a tank, the vacuum chamber formedfrom a flexible seal between the tank and a housing and a magneticapparatus that encompasses a perimeter of a damaged area of the tank;and a friction welding motor operably coupled to the vacuum chamber. 2.The apparatus of claim 1 wherein the magnetic apparatus that encompassesthe perimeter of the damaged area of the tank further comprises: sealsthat encompass the perimeter of the damaged area of a work surface; anda permanent magnet having a release lever, the permanent magnet beingplaced over the seals.
 3. The apparatus of claim 2, wherein the vacuumchamber further comprises: a fitting in the housing, wherein the housingand the fitting provide a substantially air tight seal.
 4. The apparatusof claim 3, wherein the vacuum chamber further comprises: an actuatorcoupled to the fitting on an outside of the housing.
 5. The apparatus ofclaim 1, wherein the housing further comprises: a hole through thehousing through which a vacuum hose can be operably attached.
 6. Theapparatus of claim 1 wherein the friction welding motor furthercomprises: materials that do not create sparks or an ignition source. 7.An apparatus comprising: seals that encompass a perimeter of a damagedarea of a work surface; and a permanent magnet having a release lever,the permanent magnet being placed over the seals.
 8. The apparatus ofclaim 7 further comprising a vacuum chamber encompassing the seals, thedamaged area and the permanent magnet, which prevents combustion in avicinity of the work surface.
 9. The apparatus of claim 8, wherein thevacuum chamber further comprises: a housing, the housing being separatedfrom the work surface through a flexible seal, wherein the flexible sealis not the seals that encompass the perimeter.
 10. The apparatus ofclaim 9, wherein the vacuum chamber further comprises: a fitting in thehousing, wherein the housing and the fitting provide a substantially airtight seal with the work surface.
 11. The apparatus of claim 10, whereinthe vacuum chamber further comprises: an actuator coupled to the fittingon an outside of the housing.
 12. The apparatus of claim 11, wherein thehousing further comprises: a hole through the housing through which avacuum hose can be operably attached.
 13. The apparatus of claim 12,wherein the housing is secured to the work surface by applying a vacuumto the vacuum chamber through the hole.
 14. The apparatus of claim 13further comprising: a motor operably coupled to the actuator and whereinthe motor further comprises: materials that do not create sparks or anignition source.
 15. A method comprising: placing seals to encompass aperimeter of a damaged area of a work surface; and placing a permanentmagnet over the seals, the permanent magnet having a release lever. 16.The method of claim 15 further comprising: placing a vacuum chamber toencompass the seals, the damaged area and the permanent magnet, whichprevents combustion in a vicinity of the work surface.
 17. The method ofclaim 16 wherein the vacuum chamber further comprises: coupling anactuator to a fitting on an outside of a housing of the vacuum chamber,wherein the fitting provides a substantially air tight seal between thehousing and the work surface.
 18. The method of claim 17 furthercomprising: coupling a motor to the actuator, wherein the motor furthercomprises materials that do not create sparks or an ignition source. 19.The method of claim 16 further comprising: securing a housing to thework surface through a flexible seal, the housing having a hole throughthe housing through which a vacuum hose can be operably attached. 20.The method of claim 19 further comprising: applying a vacuum to thevacuum chamber through the hole in the housing.